Download TABLE OF CONTENTS - Mustang Survival

MUSTANG SURVIVAL
DAMAGE TOLERANT LIFE PRESERVER,
MUSTANG MODELS MD4020/MD4025 FR
DESCRIPTION AND MAINTENANCE INSTRUCTIONS
MAY 11, 2007, REV: 1.1
MD4020 shown
Mustang Survival Canada
3810 Jacombs Road
Richmond, BC, V6V 1Y6
Tel: (604) 270-8631 Fax: (604) 270-0489
E-mail: mustang@mustangsurvival.com
WEB: www.mustangsurvival.com
Mustang Survival-USA
3870 Mustang Way
Bellingham, WA
USA 98226
Tel: (360) 676-1782 Fax: (360) 676-5014
E-mail: mustangusa@mustangsurvival.com
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
TABLE OF CONTENTS
1.0 INTRODUCTION................................................................................................................. 1
1.1
1.2
1.3
1.4
GENERAL ..................................................................................................................................1
CONTACT ..................................................................................................................................1
RIGHTS RESERVED .................................................................................................................1
RESPONSIBILITIES...................................................................................................................1
2.0 FEATURES......................................................................................................................... 3
2.1
DESIGN AND CONSTRUCTION ...............................................................................................3
2.2
ASSEMBLED DTLP (MD4020 SHOWN)....................................................................................3
2.3
LIFE PRESERVER.....................................................................................................................5
2.4
INFLATABLE CELL ....................................................................................................................5
2.5
AUTOMATIC CO2 INFLATION DEVICE (MD4020)....................................................................7
2.6
MANUAL CO2 INFLATION DEVICE (MD4025 FR) ....................................................................7
2.7
BEADED CO2 INFLATION HANDLE..........................................................................................8
2.8
ORAL VALVE AND PRESSURE RELIEF VALVE......................................................................8
2.9
BALLISTIC CYLINDER POUCH ................................................................................................9
2.10 PROTECTIVE CONTAINER.......................................................................................................9
2.11 HARNESS SYSTEM...................................................................................................................9
3.0 OPERATION..................................................................................................................... 13
4.0 RE-ARMING ..................................................................................................................... 14
4.1
4.2
4.3
RE-ARMING THE MD4020 ONLY ...........................................................................................14
BALLISTIC CONTAINMENT POUCH (MA4050) INSTRUCTIONS (MD4025 FR ONLY) ........17
RE-ARMING THE MD4025 FR ONLY......................................................................................20
5.0 HARNESS CONFIGURATION.......................................................................................... 22
6.0 DONNING AND PACKING INSTRUCTIONS.................................................................... 25
6.1
6.2
6.3
GENERAL ................................................................................................................................25
ASSEMBLY, FOLDING AND PACKING INSTRUCTIONS ......................................................25
DONNING.................................................................................................................................35
7.0 MAINTENANCE AND CARE ............................................................................................ 37
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
GENERAL ................................................................................................................................37
CLEANING ...............................................................................................................................37
TREATMENT AFTER IMMERSION .........................................................................................37
SERVICE LIFE .........................................................................................................................38
WORK AREA............................................................................................................................38
STORAGE ................................................................................................................................38
EQUIPMENT REQUIRED ........................................................................................................38
MAINTENANCE REPORTING .................................................................................................38
8.0 INSPECTION AND TESTING ........................................................................................... 39
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
REQUIREMENTS.....................................................................................................................39
PRE-USE AND POST-USE INSPECTION...............................................................................39
VISUAL INSPECTION..............................................................................................................39
MAINTENANCE INSPECTION ................................................................................................41
ORAL INFLATOR VALVE TEST ..............................................................................................41
RELIEF VALVE TEST ..............................................................................................................41
INFLATABLE CELL TEST........................................................................................................42
CO2 INFLATION DEVICE TEST ..............................................................................................42
i
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
8.9
CO2 CYLINDER INSPECTION AND WEIGHT TEST...............................................................43
9.0 REPAIRS .......................................................................................................................... 44
9.1
GENERAL ................................................................................................................................44
9.2
IDENTIFICATION OF DEFECTS .............................................................................................44
9.3
HARNESS OR PROTECTIVE CONTAINER............................................................................44
9.4
SEWING ...................................................................................................................................44
9.5
INFLATABLE CELL ..................................................................................................................47
9.6
LEAK LOCALIZATION .............................................................................................................47
9.7
PATCH GLUEING ....................................................................................................................47
9.8
CO2 INFLATION DEVICE.........................................................................................................48
9.9
RESTRAINT LAYER ................................................................................................................48
9.10 CO2 CYLINDER ........................................................................................................................48
10.0
11.0
11.2
11.3
11.4
11.5
11.6
SUMMARY ................................................................................................................. 49
PARTS LIST ............................................................................................................... 49
MA4050 BALLISTIC CONTAINMENT POUCH ........................................................................49
MA4012 FR EBS POCKET ASSEMBLY ..................................................................................49
MA4006 INTEGRATION STRAP..............................................................................................50
MA4013 RE-ARM KIT...............................................................................................................50
MA4014 RE-ARM KIT...............................................................................................................50
ii
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
TABLE OF FIGURES
Figure 1. Component Locations (front view) ......................................................................................... 3
Figure 2. Tactical Vest Attachments ..................................................................................................... 4
Figure 3. Duty Belt with Upper Body Harness Configuration ................................................................ 4
Figure 4. Upper Body Harness Configuration ....................................................................................... 4
Figure 5. Component Locations (rear view).......................................................................................... 5
Figure 6. Inflatable Cell ......................................................................................................................... 6
Figure 7. Automatic/Manual CO2 Inflation Device – Non-Operated/Ready Position............................. 7
Figure 8. Manual CO2 Inflation Device.................................................................................................. 8
Figure 9. MA4050 Ballistic Cylinder Pouch........................................................................................... 9
Figure 10. MD4020 Harness System.................................................................................................... 10
Figure 11. Eight adjustment points ....................................................................................................... 10
Figure 12. DTLP Tactical Vest Front and Rear Attachment Points....................................................... 11
Figure 13. Side-release Buckles ........................................................................................................... 11
Figure 14. Accessory Strap Addition..................................................................................................... 12
Figure 15. Step a. Re-arming Your MD4020 ........................................................................................ 14
Figure 16. Step b. Re-arming Your MD4020 ........................................................................................ 14
Figure 17. Step c. Re-arming Your MD4020......................................................................................... 15
Figure 18. Step d. Re-arming Your MD4020 ........................................................................................ 15
Figure 19. Step e. Re-arming Your MD4020 ........................................................................................ 15
Figure 20. Step f. Re-arming Your MD4020 ......................................................................................... 16
Figure 21. Step g. Re-arming Your MD4020 ........................................................................................ 16
Figure 22. Step h. Re-arming Your MD4020 ........................................................................................ 16
Figure 23. Step i. Re-arming Your MD4020.......................................................................................... 17
Figure 24. Step a. Pouch Installation Instructions................................................................................. 17
Figure 25. Step b. Pouch Installation Instructions................................................................................. 18
Figure 26. Step c. Pouch Installation Instructions................................................................................. 18
Figure 27. Step d. Pouch Installation Instructions................................................................................. 19
Figure 28. Step e. Pouch Installation Instructions................................................................................. 19
Figure 29. Step f. Pouch Installation Instructions.................................................................................. 19
Figure 30. Step a. Re-arming Your MD4025 FR................................................................................... 20
Figure 31. Step b. Re-arming Your MD4025 FR................................................................................... 20
Figure 32. Step a. Harness Assembly and Mounting............................................................................ 22
Figure 33. Step b. Protective Cover Mounting Points ........................................................................... 22
Figure 34. Step c. Webbing and Snap Attachment System at the Collar ............................................. 23
Figure 35. Step d. Closure Sequence of the Webbing and Snap Attachment System ......................... 23
Figure 36. Step e. Webbing and Snap Attachment System at the Lobe............................................... 24
Figure 37. Step f. Webbing and Snap Attachment System at the Collar .............................................. 24
Figure 38. Step b. Evacuated Inflatable Cell (MD4025 FR Shown)...................................................... 25
Figure 39. Step c. Inflatable Cell Inversion Sequencing (Left to Right) ................................................ 26
Figure 40. Step d. Layout of the Half-Inflatable Cell Shapes ................................................................ 26
Figure 41. Step e. Placement of the Inflatable Cell into the Restraint Layer ........................................ 27
Figure 42. Step f. Mounting the Inflator Assembly ................................................................................ 27
Figure 43. Step h. Inflatable Cell Assembly (MD4020 shown).............................................................. 28
Figure 44. Step j. Layout and Packing Fold 1, Right Lobe.................................................................... 29
Figure 45. Step k. Packing Folds 2 and 3, Right Lobe.......................................................................... 29
Figure 46. Step l. Packing Folds 4 and 5, Right Lobe........................................................................... 30
Figure 47. Step m. Packing Fold 6, Right Lobe .................................................................................... 31
Figure 48. Step n. Zipper Tail Closure, Right Lobe............................................................................... 31
iii
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
Figure 49. Step o. Packing Folds 7, 8 and 9, Left Lobe........................................................................ 32
Figure 50. Step p. Packing Folds 10 and 11, Left Lobe........................................................................ 33
Figure 51. Step q. Packing Folds 15 and 16, Collar ............................................................................. 33
Figure 52. Step r. Packing Fold 17 and Zipper Closure........................................................................ 34
Figure 53. Step s. Zipper Finishing and Final Arming........................................................................... 35
Figure 54. Step y. Donning Closures and Adjustment Points ............................................................... 36
Figure 55. Step a. Patching .................................................................................................................. 45
Figure 56. Step b. Patching .................................................................................................................. 46
Figure 57. Steps c., d. and e. Patching................................................................................................. 46
Figure 58. Steps f. and g. Patching....................................................................................................... 47
Figure 59. MA4050 Ballistic Containment Pouch with Cover................................................................ 49
Figure 60. MA4012 FR Pocket Assembly ............................................................................................. 49
Figure 61. MA4006 Integration Strap.................................................................................................... 50
iv
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
1.0
INTRODUCTION
1.1
GENERAL
1.1.1
The MD4020 and MD4025 FR Damage Tolerant Life Preservers (DTLPs) are each comprised
of a life preserver and mounting harness assembly. These devices are designed to operate in
any scenario regardless of ballistic damage or penetration of a lobe.
1.1.2
The MD4020 is designed primarily for marine boarding parties that are performing tactical
ship-boarding operations on a potentially hostile vessel. In the event of an accidental manoverboard or in the possible event of being struck by firearm discharge, this device
automatically inflates and self rights an unconscious user (US Patent 6,452,840).
1.1.3
The MD4020 life preserver is universal in size and fit and uses an automatic inflator. The
standard color is black and the materials are non-FR.
1.1.4
The MD4025 FR is primarily used by aviation aircrew and passengers in hostile operating
environments. The MD4025 FR is configured with a manual inflator and in the event of an
emergency egress or in the possible event of being struck by firearm discharge, this device
self rights a conscious user when inflated (US Patent 6,452,840).
1.1.5
The olive drab, fire-retardant MD4025 FR conforms to Air Standard ASCC 61/102/18
requirements. The harness can be adjusted with the eight adjustment points to fit an individual.
1.2
CONTACT
1.2.1
For further information concerning this manual or the DTLP, contact:
Mustang Survival Corp.
3810 Jacombs Road
Richmond, BC, Canada
V6V 1Y6
Tel. (604) 270-8631
Fax (604) 270-0489
E-mail: mustang@mustangsurvival.com
WEB: www.mustangsurvival.com
1.3
RIGHTS RESERVED
1.3.1
Velcro is a trademark of American Velcro Inc.
1.4
RESPONSIBILITIES
1.4.1
The individual to whom the DTLP is issued or assigned, following internal training, assumes
responsibility for pre and post use inspections and for returning the DTLP to the Maintenance
Shop for periodic inspection and testing on required dates.
1
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
1.4.2
Each operational organization is responsible for the instruction and survival training of all
DTLP users in the following:
a. Fitting and operation of the DTLP.
b. Purpose, use and operation of all DTLP furnished equipment accessories.
c. Importance and method of visual pre and post use inspections.
1.4.3
The Maintenance Shop is responsible for:
a. Periodic inspection and testing of the DTLP.
NOTE: The inspection interval should not exceed 180 days (see section 8.0).
b. Inspection when first issued from a Supply Depot or contractor and prior to issue for
service.
c. Maintenance, cleaning, and repair if and when required.
d. Ensuring that a fully charged carbon dioxide (CO2) cylinder, automatic bobbin and
functional CO2 inflation device are properly installed prior to issue.
e. Requisitioning and maintaining stocks of spare parts.
f.
1.4.4
Maintenance of inspection records of all MD4020 and MD4025 FR units.
Testing
1.4.4.1 All DTLPs are tested to ensure the highest level of reliability and performance. Mustang
Survival offers superior quality under rigid QA standards which are certified to ISO-9001.
1.4.5
Fit
1.4.5.1 When a DTLP unit is initially issued to personnel, it is to be individually fitted to the wearer.
The wearer is to be fully instructed in the donning and adjustment procedures.
2
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
2.0
FEATURES
2.1
DESIGN AND CONSTRUCTION
2.1.1
General
2.1.1.1 Mustang Survival MD4020 and MD4025 FR DTLPs are designed to provide flotation in case of
immersion in water, minimizing the risk of drowning. This DTLP inflates manually (MD4025
FR) or automatically (MD4020), upon water immersion. It is also designed to worn over top of
body armour and in the event of direct ballistic penetration to one lobe, has a redundant
system that will provide a fully functional life preserver.
2.1.1.2 The FR version (MD4025 FR) is made of fire retardant materials.
2.1.2
Familiarize yourself with all the features of the DTLP to maximize its effectiveness. Illustrations
are provided to support the text.
NOTE: All location reference points in this section are based from the perspective of
the person wearing the DTLP.
2.2
ASSEMBLED DTLP (MD4020 SHOWN)
Figure 1. Component Locations (front view)
Protective Cover
Harness Assembly
Main Buckle
Adjustment Points
Thigh Strap
Beaded Inflation Handles
3
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
Figure 2. Tactical Vest Attachments
Figure 3. Duty Belt with Upper Body Harness Configuration
Figure 4. Upper Body Harness Configuration
4
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
Figure 5. Component Locations (rear view)
Protective Cover
Attachment Points
Velcro Tab
Breakout Point
Adjustment Points
Thigh Strap
2.3
LIFE PRESERVER
2.3.1
The life preserver assembly consists of four major components:
a. Inflatable Cells
b. Restraint Layer
c. Protective Container
d. Harness Assembly
2.3.2
The life preserver cover is attached directly to the mounting harness assembly with an
interlocking webbing and snap system at four points and is easily removable. Attached to the
life preserver cover, also with an interlocking webbing and snap system at four points, is the
inflatable cell restraint layer and associated inflatable cells. The four attachment points for both
interfaces are at each lobe (right and left) and the collar (right and left). The inflatable cell,
when folded and packed, is contained within the protective container by means of a perimeter
zipper closure system (US Patent 6,832,415) and a Velcro patch located at the rear at the
zipper ends at the rear collar.
2.4
INFLATABLE CELL
2.4.1
The inflatable cells are made from polyurethane coated nylon fabric. The perimeter of each
cell is sealed using radio frequency (RF) bonding.
5
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
Figure 6. Inflatable Cell
Lifting Strap
Reflective Tape
Restraint Layer
Buddy Line
Sea Light
MA4050
Ballistic Pouch
for Cylinder
Bladder Access
Zipper
Inflator
Activation
Lanyard
Pressure Dump
/ Relief Valve
Right Lobe
2.4.2
The life preserver comprises two discrete inflatable cells (or chambers, right and left, each of
which operate independent of one another. Each inflatable cell is inverted on itself and placed
into one half of the restraint layer (either right or left). When activated, the device will operate
as a fully functional Personal Flotation Device (PFD) with either or both chambers deployed. If
both chambers are deployed, either cell will inflate into either one another to fill the restraint
layer. If only one of the two inflatable cells is activated, the cell will inflate into the opposite
chamber (i.e.: the non-activated side) to fill the restraint layer (US Patent 6,452,840). Excess
inflation gas is vented through a breather valve (or pressure relief/dump valve) on each
chamber.
WARNING: The MD4020 DTLP is configured with an automatic inflation system and will
inflate when immersed in at least 4 inches (10 cm) of water.
2.4.3
Normal manual or automatic inflation by carbon dioxide gas (CO2) from a stored cylinder, fully
inflates either chamber. Either chamber may be inflated by mouth, and provides for
redundancy in an event one of the chambers is damaged, requires topping up, or fails to
operate for any reason. Air can also be vented using the same valve to provide lower pressure
cells for additional comfort or mobility. The dump valve (if included) provides for rapid
deflation.
2.4.4
When inflated, the cell forms a yoke around the back of the user's neck, extending into two
lobes down the user's chest.
2.4.5
A webbing and snap assembly is used to attach the components to one another. Webbing
straps are flaked in and out of small 1” slots and doubled back on one another before being
6
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
secured with a ‘pull-the-dot’ snap. This provides a secure anchor that prevents mobility or
rotation about these attachment points.
2.4.6
The largest inflatable cell is designed to provide a minimum buoyant force of 29.5 kg (65 lb),
when fully inflated with 60 grams of carbon dioxide (CO2) gas stored in a cylinder in ambient
temperatures above 0° C (32° F).
2.5
AUTOMATIC CO2 INFLATION DEVICE (MD4020)
2.5.1
The MD4020 incorporates an automatically operated inflation device. The operating
components of the automatic inflation device (Hammar Auto Inflator) shown in figure 7.
2.5.2
For the MD4020, there are two automatic inflation devices: one located on each inflatable cell.
The inflation device for the left cell is located on the rear left lobe towards the body, and the
inflation device for the right cell is located on the front of the right lobe (away from the body on
the front side of the inflatable). The inflation device is secured with an inner and outer
component which interfaces with either side of the sealing ring (RF welded to the bladder). A
60g carbon dioxide (CO2) cylinder is threaded into the inner portion of the inflation device.
Hydrostatic pressure is applied to objects submerged in water. The hydrostatic inflator needs
only to be submerged 4 inches (10 cm) for the hydrostatic pressure to open a pressure valve
releasing a firing mechanism, automatically inflating the PFD. Inflating under hydrostatic
pressure, the PFD will not inflate prematurely due to rain, humidity or water contact (the PFD
can be inflated manually by pulling the activation cord). Easily view the inflator replacement
date and inflator status through the safety inspection window - green indicates ready for use.
See re-arm instructions in section 4.1.
Figure 7. Automatic/Manual CO2 Inflation Device – Non-Operated/Ready Position
2.6
MANUAL CO2 INFLATION DEVICE (MD4025 FR)
2.6.1
The MD4025 FR incorporates a manually operated inflation device. The operating components
of the automatic inflation device (Halkey-Roberts HD7714-9 6FManual Inflator). See re-arm
instructions in section 4.2.
7
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
Figure 8. Manual CO2 Inflation Device
CO2 Cylinder
Manual Inflator
Lever in the Up and
Ready Position
Indicator Tab
Lanyard
Beaded Handle
2.7
BEADED CO2 INFLATION HANDLE
2.7.1
The beaded inflation handles are constructed of five black plastic beads threaded onto a loop
of nylon webbing. The handles are attached with a lanyard to the operating levers of each CO2
inflation device and snapped to the lower side of each lobe of protective container. The
beaded handle is designed to be easily visible and provide a positive grip for inflation of the
preserver with cold, wet or gloved hands.
2.8
ORAL VALVE AND PRESSURE RELIEF VALVE
2.8.1
Two oral inflator valve and pressure relief valve assemblies are attached to the inflatable cells
(one each cell). The assemblies are RF (Radio-Frequency) bonded to the inflatable cell. Each
oral valve and pressure relief valve accesses a separate independent chamber.
2.8.2
The oral inflator located on the rear left lobe of the inflatable cell inflates/deflates the left
chamber. This relief valve is used to regulate the pressure in the left lobe of life preserver or
can be manually activated to dump the gas from the cell in an emergency.
2.8.3
The oral inflator located on the front right lobe of the inflatable cell inflates/deflates the right
chamber. This relief valve is also used to regulate the pressure in the right lobe of the life
preserver or can be manually activated to dump the gas from the cell in an emergency.
2.8.4
Both inflators also provide a means of "topping-up" the cell to compensate for normal leakage
or under-inflation due to excessively cold temperatures. As well, these oral inflators provide a
means for cell deflation, which may be necessary in the event when both cylinders are
simultaneously inflated (either manually or automatically). The relief valve is designed to begin
venting at pressures greater than 2.0 psi to ensure proper inflation to form and breakout of the
protective container. The DTLP concept requires a higher dynamic working pressure during
the inflation stages.
8
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
2.9
BALLISTIC CYLINDER POUCH
2.9.1
The MD4025 FR offers CO2 cylinder containment (MA4050) (Patent Pending by Pacific Safety
Products) in the event of ballistic penetration. If unprotected, ballistic impact to the cylinder can
cause fragmentation or cause the cylinder to become a hazardous projectile itself.
Figure 9. MA4050 Ballistic Cylinder Pouch
2.10
PROTECTIVE CONTAINER
2.10.1
The protective outer container is constructed of a durable black 420 denier rip-stop nylon
(MD4020) or sage green 6oz/yd2 Nomex IIIA® aramid (MD4025). The container incorporates
Mustang’s patented Secure-Zip™ closure system (US Patent 6,832,415). The zippered
enclosure can be opened via the break-away point at the back of the collar.
2.10.2
The protective container is constructed of heavy black Cordura nylon cloth (MD4020) or sage
green Nomex (MD4025 FR). It is attached directly to the harness assembly with a webbing
and snap attachment system. The container houses the life preserver (i.e.: restraint layer and
two inflatable cells contained therein), providing a compact protective enclosure that optimizes
mobility and comfort in the undeployed configuration.
2.10.3
The restraint layer is attached directly to the inside of the protective container with a webbing
and snap attachment system. The cell is neatly folded and packed within the container, which
in turn is secured in the closed position with a system of slide fasteners, and a Velcro™ tab.
The tail ends of the slide fastener tapes are protected by 'tucking' the tails into the lower
openings of the secured container to finish the closure.
2.10.4
The container’s slide fastener closure is closed with separate sliders on each half of the
container. The zippers are backed over the open zipper teeth and re-closed to secure the
closure (US Patent 6,832,415).
2.10.5
The inflation handle lanyard passes through the hole in the container that accommodates the
zipper tail at the bottom of each container lobe and is attached at the beaded handle by
Velcro™.
2.11
HARNESS SYSTEM
2.11.1
The life preserver is intended to be secured to the user using the (black or green) harness
system. The standard harness system consists of a light-weight full-body harness that covers
the torso and thighs. The harness has four attachment points that secure the protective
container (and life preserver) to the front (2) and back (2) of the torso section using a webbing
9
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
and snap attachment system. The front attachment has two adjacent snaps on either
attachment point to improve life preserver stability. The webbing on the harness crosses over
the back, crosses over each hip, and runs around the waist and thighs of the user. The device
is donned by opening and closing 3 side-release buckles: one at the waist and one at each
thigh.
Figure 10. MD4020 Harness System
2.11.2
There are 8 adjustment points on the harness system, both right and left for each: waist
adjustment, back adjustment, hip adjustment and thigh adjustment. All adjustments should be
made so that the harness and life preserver is snug on the body, but allows user flexibility and
mobility. Elastic retainers are fit onto each adjustment webbing to secure excess strapping
after the harness has been adjusted. The excess strapping can be flaked into the elastic
retainers where significant lengths are left after adjustment. In addition to elastic retainers,
there are Velcro tabs at the end of each strap which can also be used to retain the strap ends
on the harness. The harness should be fit snug and secure to the body to ensure proper
performance of the life preserver. Proper fit should be verified by testing the in-water
performance of the deployed device.
Figure 11. Eight adjustment points
Waist
Hip
Back
Thigh
IMPORTANT: When properly donned, the smallest portion of the inflatable should be on
top of the shoulder, in the neck area. The back collar should be off the neck and
positioned down the back for optimum comfort.
10
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
2.11.3
If the device is worn with a tactical webbing vest, the life preserver can be separated from the
harness and affixed to such a vest using the webbing and snap attachment system. Excess
strap length is left on the back collar snap and webbing assemblies to allow either snapping or
tie closure for fit variability.
CAUTION: The life preserver should not be worn on the inside of a ballistic vest to
avoid secondary impact injuries. The device is designed to take damage and
perform as required and should be configured on the outside of any tactical
ensemble.
2.11.4
The DTLP may be attached to load carriage or tactical vests or law enforcement webbing and
harness assemblies using the two side-by-side attachment points, on the front of each lobe
and at the back of the LP (as shown).
Figure 12. DTLP Tactical Vest Front and Rear Attachment Points
2.11.5
Four-point attachment accessory straps may use side-release buckles for quick
reconfiguration.
Figure 13. Side-release Buckles
2.11.6
Accessory straps may added to accommodate a law enforcement belt or attach to a tactical
vest.
11
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
Figure 14. Accessory Strap Addition
12
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
3.0
OPERATION
CAUTION: Relief Valve blockage can cause valve malfunction. Malfunction of both
pressure relief valves will cause over-pressurization and will over-stress the
inflatable cell. Both chambers of the cell must be completely evacuated of any
residual air or carbon dioxide gas prior to CO2 inflation.
3.1.1
Manual operation of the life preserver is accomplished by grasping either or both beaded
inflation handles located on the lower side of the protective container. Jerking sharply
downwards rotates the operating lever of the CO2 inflation device, which in turn forces the
piercing pin to puncture the neck of the CO2 cylinder and allow the compressed gas to flow
into the inflatable cell. Only one of the inflation cells needs to be manually activated (either left
or right, whichever is most accessible) for the life preserver to be operational. When the
MD4020 comes in contact with the water, the un-deployed inflation cell will fire (but vent to
atmosphere), unless configured manually.
3.1.2
Firing both cells simultaneously will also deploy the device and excess gas will be vented
through the pressure relief valves.
3.1.3
The MD4020 can be configured manually if desired (consult Mustang Survival for this
modification). Advantages to manual inflation are: minimized probability of inadvertent inflation,
movement through “over-the-waist” water without inflation, and conservation of inflation
cylinders. Disadvantages to manual inflation are: no automatic inflation for unconscious users,
no automatic inflation for incapacitated users, and no automatic redundancy. The MD4025 FR
has no automatic inflation capability and must be manually activated.
3.1.4
The pressure of the expanding gas forces the fasteners around the periphery of the protective
container to separate, automatically opening the protective container and allowing the cell to
reach its fully inflated shape.
NOTE: Carbon dioxide gas does not remain in the life preserver indefinitely. Either of
the oral inflator valves can be used as a means of compensating for normal cell
leakage. The oral inflators are also provided as an emergency back up in the
unlikely event that the CO2 inflation device fails.
13
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
4.0
RE-ARMING
4.1
RE-ARMING THE MD4020 ONLY
NOTE: Use a valid Mustang Survival re-arm kit (MA4013) for this procedure. Use of
other re-arm kits may result in improper operation or failure to operate and will
void the product’s warranty.
a. In order to access the inflator system, partially open the cover by unzipping the closure
(near the slider tucked into the end of the cover). After retrieving the zipper tail, the slider
can be opened to mid-lobe height. Carefully open the cover and unfold the bladder. To
avoid inadvertent inflation, detach the beaded handle while re-arming. Hold the CO2
cylinder through the fabric, using one hand (Fig. 15).
Figure 15. Step a. Re-arming Your MD4020
b. Insert the metal key between the black locking ring and labeled yellow cap. Turn the key
counter-clockwise (Fig. 16).
Figure 16. Step b. Re-arming Your MD4020
Locking Ring
Key
c. Turn the black locking ring counter-clockwise and lift off the cap (yellow inflator operating
head Fig. 17). Dispose of the used cap.
14
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
Figure 17. Step c. Re-arming Your MD4020
Cap
d. Squeeze the sealing ring to elongate and remove the inflator body through the sealing
ring (Fig. 18).
Figure 18. Step d. Re-arming Your MD4020
Red Indicator
Inflator Body
Sealing Ring
e. Dispose of the used inflator body.
Figure 19. Step e. Re-arming Your MD4020
Red Indicator
Trash
15
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
f. Check that the new inflator body indicator is green. Insert the new inflator body with CO2
cylinder pointing upward inside the Inflatable PFD (Fig. 20). Let the sealing ring rest on
the adapter around the four lugs.
Figure 20. Step f. Re-arming Your MD4020
Green Indicator
Caution: Do not turn
the center shaft
g. Now check the new manual/automatic cap as follows (Fig. 21):
1. Is the single point status indicator showing green?
2. Is the expiry date OK?
If YES is the answer to both questions, then proceed as follows. If the answer is NO to
either question, get a new cap.
Figure 21. Step g. Re-arming Your MD4020
Water Inlet Valve
Single Point
Indicator
h. Hold the CO2 cylinder through the fabric of the Inflatable PFD (Fig. 22). Position the
replacement cap with the water inlet valve pointing to the right and press firmly onto the
inflator body and sealing ring (Fig. 22).
Figure 22. Step h. Re-arming Your MD4020
16
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
i. While pressing FIRMLY onto the inflator body, turn the BLACK locking ring clockwise into
the locked position (Fig. 23). Pull on the cap to make sure it has locked onto the inflator
body.
Figure 23. Step i. Re-arming Your MD4020
Black Locking Ring
j. Check: To see that the single point status indicator on the cap is green, the pull to inflate
lanyard is present and that the locking ring is locked.
4.2
BALLISTIC CONTAINMENT POUCH (MA4050) INSTRUCTIONS (MD4025 FR ONLY)
4.2.1
The Ballistic Containment Pouch instructions are for use with Mustang Survival Inflatable
PFDs with Halkey-Roberts 6F inflators (manual or automatic).
NOTE: Use with other manufacturer’s PFDs may result in improper operation or failure
to operate and will void the product’s warranty.
4.2.2
Pouch Installation Instructions
a. Gather an unused Ballistic Containment Pouch (MA4050) and Inflatable PFD (without
cylinder). Note the parts displayed in the illustration. Remove any parts from the inflator
post for pouch installation.
NOTE: The inflatable cell shown in the following section is not the same as the
MD4020 or MD4025 FR. However, it is adequate for this instruction.
Figure 24. Step a. Pouch Installation Instructions
b. Center the hole on the Ballistic Containment Pouch tether strap over the inflator post to
ensure it does not interfere with the sealing surface (interface between the gasket and the
inflator) when inflator is attached. Now place the bottom (thicker) gasket, inflator body
17
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
and top gasket over the inflator post. Screw the inflator cap nut onto the post using a
torque wrench to 30 lb-in.
CAUTION: Incorrect placement can cause PFD malfunction.
Figure 25. Step b. Pouch Installation Instructions
c. Insert the new unused cylinder into the inflator through the main pouch opening (threaded
end first). Slide the pouch down to expose the cylinder. Rotate the cylinder clockwise to a
tight fit into the inflator. Manipulate the cylinder towards the centre of the pouch so it is
securely held in the cup area. Replace bobbin and/or arming pin as required.
Figure 26. Step c. Pouch Installation Instructions
d. Fold the Ballistic Containment Pouch out flat.
18
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
Figure 27. Step d. Pouch Installation Instructions
e. Fold the Ballistic Containment Pouch to form a zig-zag pattern around the cylinder (end
view).
Figure 28. Step e. Pouch Installation Instructions
f. Once folded, pinch the ends of the folded Ballistic Containment Pouch and cylinder and
insert into the black nylon cover. Leave the tether strap outside of nylon pouch.
Figure 29. Step f. Pouch Installation Instructions
g. Repack the PFD using the instructions found in RE-ARMING THE MD4025 FR ONLY.
19
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
4.3
RE-ARMING THE MD4025 FR ONLY
i.
Each automatic inflator assembly requires arming prior to packing.
ii.
A CO2 cylinder and green indicator pin are required for replacement, re-arm
kit MA4014.
iii.
See the BALLISTIC CONTAINMENT POUCH (MA4050) I, if required, before
proceeding.
NOTE: Use a valid Mustang Survival re-arm kit (MA4014) for this procedure. Use of
other re-arm kits may result in improper operation or failure to operate and will
void the product’s warranty.
a. To re-arm your Inflatable PFD, simply unscrew and discard the used CO2 cylinder (Fig.
30). In order to access the inflator system, partially open the cover by unzipping the
closure (near the slider tucked into the end of the cover). After retrieving the zipper tail,
the slider can be opened to mid-lobe height. Carefully open the cover and unfold the
bladder. To avoid inadvertent inflation, detach the beaded handle while re-arming.
Figure 30. Step a. Re-arming Your MD4025 FR
b. To check that the inflator is fully operational, remove the indicator tab and pull down on
the lanyard and see if the piercing pin travels freely. Both the head and lever should
easily return to their original position (Fig. 31).
Figure 31. Step b. Re-arming Your MD4025 FR
Piercing Pin
Indicator Tab
Pull Down
c. After using your Inflatable PFD, always rinse it with tap water to remove dirt and salt. Let
dry before re-arming.
d. Remove the cap nut.
e. Remove the upper sealing gasket and CO2 inflation device by lifting it off the inflation
manifold valve.
f. Inspect the lower sealing gasket (still on manifold valve) and upper sealing gasket. If
defective, deteriorated or cracked, replace with a new gasket.
g. Remove and replace the core valve, if necessary.
20
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
h. Reinstall the CO2 inflation device and upper gasket. Ensure that the MA4050 Ballistic
Pouch does not compromise the gasket seal, if applicable.
i. Install a cap nut and tighten to a torque of 8.0 inch-pounds using a calibrated torque
wrench.
j. With the manual lever in the up-and-ready position install the indicator tab into the
inflator. Screw the new CO2 cylinder hand-tight into the inflator (Fig.31). Do not over
tighten as this can damage the internal gasket.
k. Refold the PFD according to the repacking instructions (see section 6.2).
l. Repeat the same process for the inflator assembly on the opposite lobe. The left lobe
inflator assembly will be on the back side of the inflatable cell assembly restraint layer
and will be facing the work table.
m. Perform the CO2 Inflation Device Test outlined in section 8.8.
CAUTION: Once the device is armed, be careful not to accidentally pull or snag one of
the inflation lanyards or the device may fire and inflate.
21
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
5.0
HARNESS CONFIGURATION
5.1
Once the inflatable cells and restraint layer have been assembled, they can be attached to the
other components of the life preserver.
a. Beginning with the harness, lay the unassembled unit flat out onto the work space, with
the back facing the work table. If the protective cover and inflatable cell assembly are
already assembled to the harness, then skip to Step a (Figure 32) and proceed with
packing the life preserver.
Figure 32. Step a. Harness Assembly and Mounting
Harness
NOTE: If the harness assembly has not been disassembled, proceed to step m.
b. Using the four mounting points (2 on the back and 2 on the front waist belt), assemble the
protective cover to the harness assembly. Ensure that the webbing is oriented correctly
prior to assembly, as shown in Figure 33. The back mounting points are folded forward to
attach to the back of the collar. The right and left lobe each have 2 discreet webbing and
snap assemblies at their respective mounting points to prevent inflatable cell rotation
when in the water.
Figure 33. Step b. Protective Cover Mounting Points
Mounting
Points
c. All attachment points are typical and are referred to as “webbing and snap attachment
systems”. They consist of flaking a webbing strap in and out of small webbing passthroughs and securing with a “pull-the-dot” snap fastener for secure mounting (see Figure
34). The pass-through on each respective sub-assembly runs adjacent to one another to
make a continuous tunnel for the webbing strap.
22
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
Figure 34. Step c. Webbing and Snap Attachment System at the Collar
“Pull-the-Dot”
Snap Fastener
d. The strap mounted on the protective cover is fed through the harness assembly’s passthrough. It is then fed through the protective cover’s passed-through, effectively “lacing”
the two bodies together. The webbing is then turned over the second pass-through loop
and attached to the “pull-the-dot” snap socket mounted on the assembly. Once the snap
dome is secured, the excess webbing can be tucked back into the loop assembly. If the
excess webbing is atypically long, it can be re-flaked until all excess lengths have been
secured. Repeat the same process for both mounting points on the back collar.
NOTE: The first pass-through or loop that the webbing strap passes through is
always on the opposite device that the strap is mounted on. For example, if the
strap is mounted onto the protective cover, then the first pass-through is on
the respective harness loop being mounted to.
Figure 35. Step d. Closure Sequence of the Webbing and Snap Attachment System
e. The protective cover’s lobes are mounted to the back collar similarly (as illustrated in
Step d, Figure 35), except there are two adjacent webbing and snap attachment
assemblies on each lobe. Each step must be simultaneously performed on each of the
adjacent straps in order to complete both assemblies. Repeat the same process for both
mounting points on the opposite lobe.
WARNING: Failure to close both snap and webbing assemblies on each lobe may
result in malfunction of the life preserver by improper flotation performance.
23
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
Figure 36. Step e. Webbing and Snap Attachment System at the Lobe
“Pull-the-Dot”
Snap Fasteners
f. After the harness has been secured to the protective cover, the protective cover can then
be secured to the inflatable cell assembly (restraint layer and inflatable cells). Using the
four mounting points (2 on the back of the collar and 1 on each lobe), assemble the
inflatable cell assembly and the protective cover (similar to the sequence illustrated in
Step d, Figure 35). Repeat the same process for each discrete attachment point.
Figure 37. Step f. Webbing and Snap Attachment System at the Collar
Collar
Mounting
Points
g. See section 2.11 for Harness Configuration information.
24
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
6.0
DONNING AND PACKING INSTRUCTIONS
6.1
GENERAL
WARNING: The MD4020 and MD4025 FR must be worn with all life preserver
components fully assembled. The modules are not to be worn separately unless
otherwise stated in this document. A loss of protection and wear resistance may
result if worn improperly.
6.2
ASSEMBLY, FOLDING AND PACKING INSTRUCTIONS
6.2.1
To assembly, fold and pack the DTLP:
NOTE: All location reference points in this section are based from the perspective of
the person wearing the DTLP (i.e.: “right” is the wearer’s right side).
NOTE: These instructions are illustrated from the life preserver when it is completely
disassembled. Disassembly of the life preserver is performed by following the
instructions in reverse order.
a. Lay the DTLP and it’s sub-components out on a flat, clean surface.
NOTE: If the DTLP has not been deployed, or one of the cells has not been deployed.
Then the bladder does not need to be removed from the restraint layer. Proceed to
step h. (for the undeployed bladder only).
b. If the DTLP is fully assembled, remove the inflatable cells by unzipping the protective
cover from the Velcro™ break-out tab at the back of the collar, removing the inflator
lanyard tab, removing the automatic inflator assemblies (see Step f, Figure 42) and
removing the inflatable cells from the restraint layer via the 3 inflatable cell access
zippers. Beginning with the removed inflatable cells (both right and left), ensure that
each cell chamber is completely evacuated prior to proceeding. Once all residual gas
has been removed from the inflatable cell, lay the inflatable cell flat and pull all
significant wrinkles out of the evacuated cell. If the cell has not been deployed it may still
be in a half-packed orientation. If it is in the half-packed position, then skip to Step e
(Figure 41) as the inflatable cell can be evacuated without fully flattening the device in
it’s single-layer.
Figure 38. Step b. Evacuated Inflatable Cell (MD4025 FR Shown)
Oral Inflator
Manifold Valve
Access Zipper
25
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
c. At the bottom lobe opposite to the inflator manifold and oral tube assembly begin to
invert the inflatable cell on itself (this will be the left side of the right inflatable cell and
vice-versa). Using the fingertips, grasp both sides of the inflatable cell wall at the bottom
of the lobe and separate the inflatable cell walls under vacuum. As the bottom edge of
the lobe is drawn inward, assist it further into the inflatable cell cavity by pushing with the
tip of your fingers to begin the inversion of the inflatable cell on itself. Continue to invert
the left lobe until it is completely pushed into the inner cavity of the right lobe. Flatten the
lobe by ensuring that the left lobe is forced into the extremities of the right inflatable cell.
Once the inflatable cell is flattened, the finished shape will be exactly half of the initial
inflatable cell shape. Repeat the same process for the second inflatable cell.
NOTE: Both inflatable cells are identical and only differ by how they are packed into the
restraint layer. Each inflatable cell can be substituted for one another (i.e.: right
for left, or vice-versa) as long as it passes inspection and testing criteria outlined
in Section 8.0.
CAUTION: Proper operation of the device depends on the proper packing sequence.
Complete evacuation, flattening of the inflatable cell and careful folding will
ensure proper deployment.
Figure 39. Step c. Inflatable Cell Inversion Sequencing (Left to Right)
d. Once both inflatable cells are inverted into half-inflatable cell shapes, they will be placed
opposite each other to make up the left and right inflatable cells. The left inflatable cell
will have the manifold and oral tube assemblies facing toward the work table, and the
right inflatable cell will have these assemblies facing away from the table.
Figure 40. Step d. Layout of the Half-Inflatable Cell Shapes
Oral Inflator
Right
Inflatable
Cell
e. Beginning with the right inflatable cell, place one of the inflatable cells into the restraint
layer through the right lobe access zipper. Feed the oral tube and inflator assemblies
through the respective pass-throughs (on the right lobe, these should be on the top face
of the restraint layer on the same side of the inflation system). Push the inflatable cell out
26
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
to the seams of the restraint layer so that the entire assembly is flattened. Ensure that
the top end of the inflatable cell is on the top side of the baffle in the collar section of the
restraint layer. Repeat the same process for the second inflatable cell, except ensure
that the tope end of the inflatable cell is on the bottom (or opposite) side of the baffle in
the collar of the restraint layer. Close all 3 access zippers on the restraint layer.
WARNING: Failure to place the inflatable cells on opposite sides of the separation
baffle in the collar section of the restraint layer may result in malfunction of the
life preserver by improper deployment of the inflatable cell.
WARNING: Failure to close the access zippers on the restraint layer could result in
malfunction or catastrophic failure of the life preserver by improper restraint.
Figure 41. Step e. Placement of the Inflatable Cell into the Restraint Layer
Restraint
Layer
Baffle
f.
For the MD4025 FR only. Once the access zippers have been closed on the restraint
layer, the inflator assemblies can be re-mounted onto the manifold valve on each cell.
Ensure that a new bottom gasket and top gasket are used if the existing components are
old or show any degradation for proper sealing. Using a 9/16” calibrated torque wrench,
install the cap nut and tighten to a torque of 8.0 inch-pounds measured. Repeat the
same process for both inflator assemblies on each inflatable cell.
Figure 42. Step f. Mounting the Inflator Assembly
g. Proceed to the Harness Configuration section to ensure the harness is properly
configured.
h. Once the inflatable cell assembly has been attached to the protective cover and
harness, the attachment of the major sub-components is complete and the device is
27
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
ready for arming and packing. Ensure the buddy-line has been placed inside the
protective cover. Lay the device out flat on the table.
Figure 43. Step h. Inflatable Cell Assembly (MD4020 shown)
NOTE: If the DTLP has not been deployed, or one of the cells has not been
deployed, then the bladder does not need to be removed from the restraint
layer. Proceed to step a. (for the undeployed bladder only).
i.
Ensure the device is properly armed, see section 4.0 for re-arming instructions.
j.
Once the inflators are armed the device is ready for folding. Begin the folding procedure
with the right lobe. Fold 1 is made by folding the half of the lobe with the inflator back
over the adjacent half of the lobe. The vertical fold line should be at the edge of the
attachment point to the protective cover.
28
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
NOTE: The entire folded assembly of each lobe is required to be contained within the
footprint area of the back panel of the protective cover. Use this panel as a
reference area when packing the life preserver.
Figure 44. Step j. Layout and Packing Fold 1, Right Lobe
Vertical
Fold Line
k. The second fold is made by flaking the tip of the lobe back over the first fold, then
continue to fold in the same direction rolling the cylinder back over top inflatable cell
assembly over the back panel of the protective cover. The inflator should be on top of
the inflatable cell assembly at this point, and the left side of the right lobe should be
folded and tucked in among vertical folds.
Figure 45. Step k. Packing Folds 2 and 3, Right Lobe
l.
The fourth fold is made by folding the remaining right half of the right lobe over top of the
cylinder assembly at the edge of the attachment point to the protective cover. The fifth
fold then flakes the tip of the lobe back over the fourth fold. At this point, all vertical folds
29
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
on the right lobe are complete and the packaged inflatable cell assembly should fit within
the width of the back panel of the protective cover.
Figure 46. Step l. Packing Folds 4 and 5, Right Lobe
m. Using your thumbs to crease a horizontal fold at the base of the inflator assembly, fold
the lower portion of the flaked inflatable cell assembly over top of the inflator assembly to
make the sixth fold. The entire right lobe assembly should be folded over the back panel
of the protective cover. Ensure that the lever and lanyard have a clear sweep and pull
path toward the center of the life preserver prior to closing the protective cover zipper
closure. Alternatively, fold at the dump valve (if equipped).
WARNING: Failure to ensure that the lever and lanyard have a clear sweep and pull
path toward the centre of the device may result in life preserver malfunction by
failure to activate manually.
30
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
Figure 47. Step m. Packing Fold 6, Right Lobe
Clear
Sweep for
Lever
Relief
Valve
n. The packed right lobe can now be closed into the protective cover. Feed the beaded
inflation handle through the opening at the bottom lobe between the tail end of the
perimeter zipper and the bottom corner of the cover. While trying to apply a free forearm
or elbow on the packed lobe as to prevent unpacking, back the slider up the zipper
closure teeth. Back the zipper off until it is near the middle or top of the right lobe portion
to temporarily secure the packed contents of the lobe while packing the opposite lobe.
CAUTION: When backing up the zipper, be sure not to catch the restraint layer in the
teeth or slider to prevent tearing of the restraint layer. Use your finger to
prevent snagging.
Figure 48. Step n. Zipper Tail Closure, Right Lobe
31
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
o. The left lobe is similar, but not identical to packing the right lobe. The seventh fold (first
on the left lobe) is made by folding the half of the lobe with the inflator assembly over the
other half. This vertical fold line should be at the edge of the attachment point to the
protective cover. The eighth fold is then made by flaking the inflator assembly back over
the previous fold, and the ninth fold is an additional flake of the tip of the lobe back over
the fold prior to it. If done properly, the inflation assembly lever should swing into the
center of the life preserver (MD4025 FR only).
WARNING: Failure to ensure that the lever and lanyard have a clear sweep and pull
path toward the centre of the device may result in life preserver malfunction by
failure to activate manually.
Figure 49. Step o. Packing Folds 7, 8 and 9, Left Lobe
Vertical
Fold Line
p. The final folds on the left lobe are made by beginning with the tenth fold, which is made
by folding the remaining left half of the left lobe over top of the cylinder assembly and
inflatable cell assembly at the edge of the attachment point to the protective cover. The
eleventh fold then flakes the tip of the lobe back over the tenth fold. At this point, all
vertical folds on the left lobe are complete and the packaged inflatable cell assembly
should fit within the width of the back panel of the protective cover. Then similar to Step
m (Figure 47), using your thumbs to crease a horizontal fold at the base of the inflator
assembly, fold the lower portion of the flaked inflatable cell assembly over top of the
inflator assembly to make the twelfth fold. The entire left lobe assembly should be folded
over the back panel of the protective cover. Ensure that the lever and lanyard have a
clear sweep and pull path toward the center of the life preserver prior to closing the
protective cover zipper closure. Alternatively, fold at the relief valve (if equipped).
WARNING: Failure to ensure that the lever and lanyard have a clear sweep and pull
path toward the centre of the device may result in life preserver malfunction by
failure to activate manually.
32
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
Figure 50. Step p. Packing Folds 10 and 11, Left Lobe
Relief Valve
q. Repeat Step n (Figure 48) for the left lobe. When the zipper is at the mid-point of the
protective lobe at the end of this step, a temporary tie or elastic may be used to
temporarily secure the left lobe package. Continue the zipper back up the tape through
the narrow shoulder section ensuring that the bulk of the inflator assembly and
associated inflatable cell assembly is in the lobe cavity of the protective cover. The
narrow section of the inflatable cell assembly can be flake folded on itself twice (folds 13
and 14) as the zipper is backed over the narrow section. The collar section of the
inflatable cell assembly is then folded into the remaining cavity (the majority of free
space is near the middle back). The fifteenth fold is made by folding in vertically the left
side of the collar from the continued flake in the narrow section. The sixteenth fold is
made by then folding the back of the collar over the previous fold.
Figure 51. Step q. Packing Folds 15 and 16, Collar
33
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
r.
Fold the last protruding corner over into the center of the collar area and back the zipper
up until it hits the stop at the back center of the collar. The zipper can now be run back
along the zipper tape to close the teeth together. As the zipper begins closure, secure
the Velcro™ tab at the back of the collar to temporarily hold the end of the zipper closed
to prevent it from prematurely opening prior to the completion of the pack.
Figure 52. Step r. Packing Fold 17 and Zipper Closure
s. Remove the temporary lobe tie or elastic and close the perimeter zipper along the entire
edge of the protective container until it runs to the stop at the bottom of the lobe. Adjust
the contents of the pack until it fits the container properly, taking care to readjust any
hard points that may be against the user. Carefully pull the entire webbing assembly
from the beaded handle out of the pass-through at the bottom of the lobe and secure it
to the Velcro™ retainer at the bottom of the lobe. Tuck the excess zipper tail into the
lanyard pass-through to complete the arming of the left inflatable cell assembly. Move to
the right lobe and continue to pack the remainder of the assembly following from Step q
(Figure 51) through Step s (Figure 53) for the right lobe. The life preserver is now
completely armed and ready for use.
34
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
CAUTION: Take care to unfasten the Velcro™ tab on the collar carefully and reattach
it when the zipper is backed into the stop and closed from the collar section.
Failure to do so can cause the protective cover zipper to open prematurely.
Figure 53. Step s. Zipper Finishing and Final Arming
6.3
DONNING
6.3.1
Once the device is armed, it can be donned like a typical harness. The device is secured by 3
side-release buckles: one at the waist and one at each thigh. After these buckles have been
fastened, there are 8 adjustment points on the harness system to assure proper fit, both right
and left for each: waist adjustment, back adjustment, hip adjustment and thigh adjustment.
6.3.2
The waist adjustment is made on the lateral sides of waist belt, and is adjusted first. The
second adjustment is in each thigh loop. The third and fourth adjustment is to the front (or hip)
and back adjustments, respectively. All adjustments should be made so that the harness and
life preserver is snug on the body, but allows user flexibility and mobility.
CAUTION: The life preserver should not be worn on the inside of a ballistic vest to
avoid secondary impact injuries. The device is designed to take damage and
perform as required and should be configured on the outside of any tactical
ensemble.
6.3.3
Elastic retainers are fit onto each adjustment webbing to secure excess strapping after the
harness has been adjusted. The excess strapping can be flaked into the elastic retainers
where significant lengths are left after adjustment.
6.3.4
The harness should be fit snug and secure to the body to ensure proper performance of the
life preserver. Activation of the life preserver is performed automatically if immersed in water or
manually by pulling either or both beaded inflation handles.
35
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
CAUTION: Proper fit should be verified by testing the in-water performance of the
deployed device.
Figure 54. Step y. Donning Closures and Adjustment Points
First Adjustment
Second Adjustment
Third Adjustment
36
Fourth Adjustment
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
7.0
MAINTENANCE AND CARE
7.1
GENERAL
7.1.1
After immersion in water (other than fresh clean water), the DTLP should be rinsed thoroughly.
To increase the life of the device, it is recommended to wash the components of the DTLP
only when required.
7.2
CLEANING
7.2.1
Laundering Procedures
NOTE: Do not dry clean.
Do not use bleach or other chlorine products.
Do not use fabric softeners.
Do not tumble dry.
Do not iron.
Do not dry in front of a radiator or other source of direct heat.
Do not store in a wet condition.
a. Separate layers: protective container, harness system or restraint layer and inflatable
cell.
WARNING: The inflatable cell should not be washed. Hand clean with a moist cotton
cloth with water only.
b. Hand wash or sponge down an area of the protective container, harness system or
restraint layer in warm (100°F) soapy (using mild laundry detergent) fresh water, then
rinse with clean water. If machine washing the protective cover or restraint layer, use
the gentle cycle with a mild detergent or soap.
c. Hang to dry the layers in a well-ventilated area, which is free from direct sunlight. Ensure
the protective container, harness system or restraint layer and inflatable cell are
completely dry before reassembling.
d. Reassemble the DTLP.
7.2.1.1 To avoid mildew, hang dry the DTLP after every use, and be sure not to stow the product
away while damp.
7.3
TREATMENT AFTER IMMERSION
7.3.1
Whenever a DTLP has been immersed in water, it must be treated as specified below and
then inspected in accordance with the current authorized servicing schedule.
7.3.2
Fresh Water Immersion
7.3.2.1 Allow the DTLP to dry naturally, preferably in the open air.
NOTE: Ensure that each layer is completely dry before re-packing.
37
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
7.3.3
Salt Water Immersion
7.3.3.1 Disassemble the layers (Life Preserver and Survival Vest) and rinse thoroughly with clean,
fresh water. Allow the DTLP modules to dry naturally, preferably in the open air.
NOTE: Ensure that each layer is completely dry before re-packing.
7.3.4
Chlorinated Water Immersion
7.3.5
Immersion of the DTLP in chlorinated water is not recommended. If the DTLP is immersed in
chlorinated water, use the same washing procedure as for salt water immediately following
immersion.
7.4
SERVICE LIFE
7.4.1
The DTLP’s service life is determined on condition rather than age. DTLPs may remain in
service if properly maintained and all test and inspection results are satisfactory.
7.5
WORK AREA
7.5.1
The work area where inspection and maintenance of the DTLP is performed should be smooth
and flat, where the DTLP will not snag, tear or otherwise be punctured or damaged and should
also be cleared of all non-essential equipment and materials.
7.5.2
The working surface should be free of harmful contaminants such as oil, grease, acids or
solvents. Work areas, subject to wide temperature variations, should be avoided.
7.6
STORAGE
7.6.1
The life preservers should be stored in the following manner:
a. They are to be stored in a cool, dry area where an even temperature can be maintained.
b. They are not to be exposed to sunlight, ozone gas, or ultra violet rays, and must be kept free
from petroleum products, acids or other damaging contaminants.
7.7
EQUIPMENT REQUIRED
7.7.1
No specialty/non-standard items are required for maintenance of the DTLP.
7.8
MAINTENANCE REPORTING
7.8.1
Maintenance performed on the DTLP assembly can be logged and reported as the user’s systems
require.
7.8.2
DTLP units deemed not suitable for service should be destroyed by marking “not for service” in
permanent marker on the label and slashing the inflatable cell.
38
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
8.0
INSPECTION AND TESTING
8.1
REQUIREMENTS
8.1.1
The DTLP should be inspected at the following times, as deemed appropriate by the user's
Safety Systems Section:
a. Maintenance inspection on receipt from the supply depot.
b. Visual inspection before issue and upon return of the DTLP to the Safety Systems
Section.
c. Periodic maintenance inspection every 60-180 days, depending on usage. Relatively
frequent use requires more frequent maintenance inspections.
d. Visual inspection after every CO2 or oral inflation.
e. Maintenance inspection whenever the integrity of the DTLP is in doubt.
NOTE: Proper care of this garment is extremely important for best results and
extended service.
8.2
PRE-USE AND POST-USE INSPECTION
8.2.1
The individual to whom the DTLP is issued or assigned should carry out a visual inspection of
the harness and life preserver protective container prior to, and after, each use. The visual
inspection should consist of the steps outlined in section 8.3.3 only.
8.3
VISUAL INSPECTION
8.3.1
A visual inspection of the DTLP should consist of the following two procedures, describing the
inspection of the inflatable cells and restraint layer and the inspection of the harness and
protective container.
8.3.2
Visual Inspection of the Harness and Protective Container
8.3.3
A visual inspection of the survival vest and protective container should consist of the following:
a. Ensure it is dry inside and out.
b. Check for the presence of all components.
c. Check for excessive wear or damage to the material, particularly stiffness, discoloration,
burns, tears, abrasions, and frayed or separating edges.
d. Check for separation of seams and broken or missing stitching.
e. Ensure all metal components are intact and free from damage or corrosion.
f.
Ensure buckles are intact and operating securely.
g. Ensure all adjustment straps can be adjusted freely and smoothly.
h. Ensure the beaded CO2 inflation handle is intact and properly secured to the protective
container.
i.
Ensure the life preserver protective container is properly secured at the Velcro™ tab
found at the back collar zipper terminal.
39
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
8.3.4
Visual Inspection of the Inflatable Cells and Restraint Layer
8.3.4.1 A visual inspection of the inflatable cells and the restraint layer should consist of the following:
a. Open the protective cover by separating the Velcro™ tab at the rear collar and pulling
the zipper halves apart.
b. Ensure the life preserver inflatable cell is properly secured to the protective container.
c. Open the three cell access zippers on the restraint layer to inspect the cell. Pull each cell
out of the lower access zippers to inspect the cells.
d. Check for condition of all Radio Frequency (RF) seams and bonding. If any damage is
found (i.e. bubbling or burns in fabric, breaks, cuts or tears on weld), the cell must be
replaced.
e. Check to ensure that each cell has been inverted on itself to make a half cell shape.
CAUTION: A non-inverted cell will cause the device to perform other than as
designed may cause device malfunction.
f.
Check to ensure that each cell is on either side of the separator at the back collar of the
restraint layer. Carefully reposition the inflatable cells back into the restraint layer making
sure that the mid-section of each collar is on opposite sides of the collar baffle.
CAUTION: Cells on the same side as the baffle may bind, snag or deploy
improperly and may cause device malfunction.
g. Check the restraint layer for physical damage and excessive wear, e.g., abrasion, holes,
cuts, tears or checking. If any damage is found, the restraint layer must be replaced.
h. Check for integrity of both oral inflators/relief valve assemblies.
i.
Check for integrity of all grommets, anchor patch assemblies, and seam assemblies. If
any damage is found, the respective restraint layer must be replaced or inflatable cell
must be repaired.
j.
Remove the CO2 cylinder and ensure the cylinder has not been fired or cylinder pierced
(MD4020).
k. Where applicable (MD4025 FR), check for a green inflator status indicator.
l.
Re-install the cylinder and check for security and correct installation of the CO2 inflation
device.
m. Ensure the beaded CO2 inflation handle is properly attached to the operating lever of the
CO2 inflation device. Note any fraying at the attachment point and replace it if necessary.
n. Refold the inflatable cell and secure it within the protective container (see section 6.2 –
Folding and Packing).
CAUTION: Ensure that the cells are repositioned properly to prevent life preserver
malfunction.
40
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
8.4
MAINTENANCE INSPECTION
8.4.1
Have qualified safety systems personnel perform the maintenance inspection, an in-depth
inspection, in accordance with this manual.
8.4.2
Perform the following tests and inspections, forming the overall maintenance inspection, in this
order:
a. Remove the inflatable cells from the restraint layer and protective container. The cylinder
manifold inflation assembly must be removed to completely remove the inflator cell from
the restraint layer.
b. Perform the oral inflator valve test as per section 8.5.
c. Perform the inflatable cell test as per section 8.6.
d. Perform the CO2 inflation device test as per section 8.8.
e. Perform the CO2 cylinder weight test as per section 8.9.
f.
Reassemble the DTLP unit and perform the visual inspections as per section 8.3 above.
8.5
ORAL INFLATOR VALVE TEST
8.5.1
Test both oral inflator valves for leaks:
a. Inflate the inflatable cell chamber to a gauge pressure of 1.0 psi, through the oral tube,
or until the cell feels hard to the touch. For the MD4025 FR, ensure the oral tube is
locked in the open position.
CAUTION: Inflation of the unsupported cell (i.e. not within the restraint layer) over
2.0 psi can result in catastrophic failure of the life preserver.
b. Place a small amount of soap & water solution on the stem opening. Use care to prevent
the entry of water into the valve. A bubbling of the soap solution will indicate leakage.
c. To check the oral inflation valve for blockage; lower the pressure in the inflatable cell
chamber to 0.5 - 1.0 psig. Open the air passage by pushing the valve inwards and then
blow by mouth through the oral inflator valve. The effort required to inflate the chamber
should not be excessive and the valve must close tightly when the oral inflation is halted.
d. Consider the valve non-serviceable if it fails either test and replace it.
8.6
RELIEF VALVE TEST
8.6.1
Test both breather pressure relief valves for proper operation:
a. Ensure that the inflatable cell is installed into the restraint layer prior to inflation. With
one inflatable cell deflated, inflate the appropriate inflatable cell chamber until the relief
valve cracks and relieves the pressure in the cell. The internal pressure should not
exceed 3.0 psi.
WARNING: Inflation of the unsupported cell (i.e. not within the restraint layer) over 1.0
psi can result in premature or catastrophic failure of the life preserver.
41
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
b. Place a small amount of soap & water solution on the base opening. Use care to prevent
the entry of water into the valve. A bubbling of the soap solution will indicate proper
operation as will the notable sound of leaking overpressure air.
c. Consider the valve non-serviceable if it fails this test and replace it.
d. Use this test opportunity to re-inspect the restraint layer to look for overstressed or
damaged areas.
8.7
INFLATABLE CELL TEST
8.7.1
There are two independent inflatable cells, right and left, both of which must be tested. Prior to
any inflatable cell chamber test, it is imperative that the opposite chamber is first evacuated of
all residual gas or air. Each chamber can be accessed through the oral inflator assembly and
the CO2 inflation valve.
8.7.2
To test each inflatable cell:
a. Slowly inflate the cell chamber, through the oral inflation valve, using an oil free
pressurized airline. Inflate to a gauge pressure of 2.0 psi (140 cm/56 inches of water).
WARNING: Inflation of the unsupported cell (i.e. not within the restraint layer) over 2.0
psi can result in premature or catastrophic failure of the life preserver.
NOTE: If the cell being tested is a new item from stock, inflate each chamber of the
cell through the CO2 inflation device, rather than the oral inflation valve, to
ensure free airflow through the inflation device and manifold.
b. Allow ten minutes for pressure stabilization, then (if necessary) adjust the pressure back
to 2.0 psi gauge.
c. Hang the inflatable cell for six hours in an area where the ambient temperature can be
maintained, at or near, a constant 22°C (72°F) +/- 5°.
d. The cell chamber is serviceable if, after the six-hour period, the internal pressure in
either chamber did not drop below 0.5 psi (corrected for temperature, if necessary).
Otherwise the cell has to be repaired or replaced.
NOTE: Both chambers must be serviceable before the life preserver is to be
considered usable.
e. Evacuate the tested cell chamber completely of all residual air and repeat steps (a)
through (e) for the other cell chamber
f.
If there is evidence of leakage in any of the valves, replace the suspect valve and repeat
steps (b) through (f).
8.8
CO2 INFLATION DEVICE TEST
8.8.1
To test the inflation device, and perform the following:
a. Remove the CO2 cylinder (see section 9.8).
b. For the MD4025 FR only, ensure the cylinder seat-sealing gasket is in place. For the
MD4020, look for the green status indicator.
42
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
c. Pull the beaded inflation handle and rotate the operating lever several times to ensure a
smooth, free operation.
d. Check that there is a minimum of a 3.0 mm protrusion of the piercing pin. This is
required to ensure that the piercing pin will pierce the CO2 cylinder-sealing disc when the
inflator valve is in the operated/activated position. If the protrusion is less than 3 mm, the
device must be replaced.
e. Return the operating lever to the non-operated "ready" position.
f.
Replace the indicator tab.
g. Replace the CO2 cylinder.
8.9
CO2 CYLINDER INSPECTION AND WEIGHT TEST
8.9.1
All carbon dioxide (CO2) cylinders should be weighed and inspected regardless of whether
they are new, or previously fitted cylinders that appear to be serviceable.
8.9.2
To inspect the cylinder, perform the following:
a. Weigh the cylinder with a scale, which is accurate to 0.1 gram. The measured weight
should not be lower than the gross weight stencilled on the cylinder. Cylinders not
meeting the gross weight specifications should be retained only for training or test
purposes and must be clearly marked "NOT FOR SERVICE USE".
b. Inspect the cylinder threads for damage, the cylinder surface for nicks, dents or
ballooning and the cylinder neck-sealing disc for scratches or punctures. Cylinders
showing any damage should have the gas released under control and then are disposed
of as scrap.
43
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
9.0
REPAIRS
9.1
GENERAL
9.1.1
It is extremely important that damaged DTLPs are handled in accordance with the following
repair requirements.
9.1.2
Qualified repair personnel can perform some repairs, with adequate facilities. The
manufacturer should do all major repairs, unless otherwise authorized by Mustang Survival
Corp. This section provides some information to assist with minor or emergency repairs to the
DTLP and related components. The restraint layer is a load bearing component and is not
repairable and should be slashed and disposed of if damaged.
WARNING: No repair or sewing alteration of the restraint layer is permitted, under any
circumstance, to prevent premature inflation or catastrophic failure.
9.1.3
The proper work area is defined in section 7.5 of this document.
9.1.4
Qualified personnel should only perform repair and overhaul of the DTLP.
9.1.5
No special tooling is required to service or maintain this product.
9.1.6
The service and maintenance reporting procedures are governed by the user’s preference or
existing systems.
9.2
IDENTIFICATION OF DEFECTS
9.2.1
Defects should be identified in accordance with the inspection and testing procedures detailed
in section 8.0.
9.3
HARNESS OR PROTECTIVE CONTAINER
9.3.1
Any harness or protective container failing inspection should be repaired using the following
guidelines.
a. Replace missing parts or components from stock.
b. Clean heavily soiled areas using mild soap and water and a soft, non-abrasive nylon or
synthetic bristle brush. Other cleaning agents or solvents must not be used.
c. Re-sew worn, broken or missing stitching.
d. Replace damaged fasteners.
e. Replace corroded or damaged metal parts.
f.
Damaged or underweight CO2 cylinders must be disposed of and replaced.
g. Replace, repair or patch components with damaged fabric.
9.3.2
Those repairs requiring sewing shall be done in accordance with section 9.4.
9.4
SEWING
9.4.1
All repairs involving sewing should be done with nylon CSB bonded thread. Do seam repairs,
stitching, and joining using a single needle lockstitch, 8 to 10 stitches per inch (25 mm).
44
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
9.4.2
Securely backstitch all ends of stitching, including breaks in thread, not less than 0.5 inch (12
mm). Any raw edges of aramid fabric, which become exposed as a result of repairs, must be
surged using a four-thread serger, 10 to 12 stitches per inch (25 mm), to prevent unravelling.
The construction of all DTLP units use 5/16 ± 1/16 inch seam allowances. There shall be no
sewing repairs to the inflatable cell.
9.4.3
Damage Treatment
9.4.3.1 Cut away and patch singed, burnt or worn areas of the protective container. See section 9.4.5
for Protective container fabric patching procedure.
NOTE: Cut away material no more than 50 mm (2 inches) in diameter.
9.4.4
Repair Materials
9.4.4.1 The full description and part numbers of the materials required for repairs are detailed in
section 11.0 of this manual.
9.4.5
Protective Container Fabric Patching
9.4.5.1 The fabric colour in the following example does not reflect the actual MD4020 protective
container fabric colour.
9.4.5.2 To patch minor tears and holes on the protective container fabric:
a. Clean the area around the tear of foreign material (see figure 50).
Figure 55. Step a. Patching
45
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
b. Cut a square, or rectangle, in the damaged fabric slightly larger than the hole (see figure
51).
Figure 56. Step b. Patching
c. Cut a patch of the original material being repaired, exceeding the hole in size by not less
than 37 mm (1 ½ inch).
d. Apply the fabric patch to the outside layer of the protective container and ensure that the
weave corresponds to that of the material surrounding the repair area.
e. Single-stitch the patch to the fabric 6 mm (¼ inch) from the edge of the hole (see figure
52).
Figure 57. Steps c., d. and e. Patching
Patch stitched to
the outside layer
of the liner
f.
Roll an edge of the patch under itself and single-stitch approximately 12 mm (½ inch)
from the original stitch.
46
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
g. Repeat this for each edge of the patch, until it is secured (see figure 53).
Figure 58. Steps f. and g. Patching
12 mm (1/2”)
h. Repair closely grouped small holes or tears with one large patch, rather than several
small ones.
9.5
INFLATABLE CELL
9.5.1
Use the Inflatable Cell Test (section 8.7) to determine if patching or replacement is required.
NOTE: The inflatable cell only serves as an air barrier, where the restraint layer is the
structural shell.
9.6
LEAK LOCALIZATION
9.6.1
If an inflatable cell fails a leakage test, then the leak source should be localized prior to
patching. A suggested method to detect a leak is to partially inflate the cell (to approximately
0.5psi, or soft to touch) and place the inflatable cell submerged under a static fresh water
reservoir. Any significant leaks can be identified by a stream of escaping bubbles. Mark the
damage locations (look for more than one) and repair per the next section.
9.7
PATCH GLUEING
9.7.1
Patching will often yield effective repairs when carried out in accordance with the instructions
in this manual.
CAUTION: There must be a minimum one-inch allowance between the tear and the edge
of the patch. The maximum tear size repairable is two inches. Return suits with
larger tears to the manufacturer for repair.
a. Ensure that the damaged area is clean and dry.
b. Work on a firm, flat, clean surface.
c. Place some protection (e.g. pieces of paper) between the layers of the suit under the
tear to prevent the layers from being glued together.
d. Flatten the damaged area as much as possible.
e. Choose the correct sized patch for the tear (see CAUTION above). Place the patch over
the hole, centering it under the patch.
47
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
f.
With a pencil or pen, trace the outline of the patch on the suit.
g. Remove the patch.
h. Apply a suitable urethane-based adhesive to one side of the patch and to the outlined
area of the suit. Ensure that the adhesive is applied to the edge of the patch and the
outlined area. Firmly recap the glue tube.
i.
Wait 15 minutes.
j.
Carefully place the patch within the outlined area. Press the patch firmly with your
fingers.
k. Place a board on the patch and weight it (over 5lbs.) for at least 8 hours, or until the
adhesive is stated to be cured.
l.
Remove the protective layer and the weight.
m. Use the Inflatable Cell Test (section 8.7) to determine if the suit is ready to use.
9.8
CO2 INFLATION DEVICE
9.8.1
The CO2 inflation device is not repairable and must be replaced when proven defective. See
section 4.1 for MD4020 automatic CO2 inflation device re-arming instructions and section 4.3
to replace the MD4025 FR CO2 inflation device:
9.9
RESTRAINT LAYER
NOTE: There shall be no repairs to the restraint layer. It is an essential structural
component and must be replaced if found defective in any way.
9.10
CO2 CYLINDER
9.10.1
The carbon dioxide (CO2) cylinder must be replaced when it fails the weight test as detailed in
section 2.5, or when there is damage to the cylinder neck sealing disc, threads, or the surface
of the cylinder. Use re-arm kit MA4013 for the MD4020 and re-arm kit MA4014 for the MD4025
FR.
48
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
10.0
SUMMARY
10.1
The Mustang Survival MD4020 is an emergency use DTLP that protects boarding parties in
harsh marine environments by providing flotation and maintaining the individual in a face-up
position. The MD4025 FR is primarily used by aviation aircrew and passengers in hostile
operating environments. These DTLPs are easily donned, maintained and stored. Qualified
approved technicians, with proper equipment, or Mustang Survival Corp. may make DTLP
repairs. A well-maintained DTLP means survival in emergency situations for which normal
clothes were not designed.
11.0
PARTS LIST
11.1
Contact Mustang Survival to obtain the following DTLP accessories.
11.2
MA4050 BALLISTIC CONTAINMENT POUCH
11.2.1
The MA4050 Ballistic Containment Pouch, which may be used with the MD4025 FR, is
available from Mustang Survival.
Figure 59. MA4050 Ballistic Containment Pouch with Cover
11.3
MA4012 FR EBS POCKET ASSEMBLY
11.3.1
The MA4012 FR Pocket Assembly, which may be used with the MD4025 FR, is available from
Mustang Survival.
Figure 60. MA4012 FR Pocket Assembly
49
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.
Mustang Survival MD4020/MD4025 FR DTLP
Description and Maintenance Instructions
11 May 2007, Rev: 1.1
11.4
MA4006 INTEGRATION STRAP
11.4.1
The MA4006 Integration Strap, which may be used with either the MD4020 or MD4025 FR, is
available from Mustang Survival.
Figure 61. MA4006 Integration Strap
11.5
MA4013 RE-ARM KIT
11.5.1
The MA4013 Re-arm Kit, which may be used with the MD4020, is available from Mustang
Survival. The MA4013 Re-arm Kit includes a Hammar inflator with 60 gr. CO2 cylinder, re-arm
key and re-arm instructions.
11.5.2
Two re-arm kits will be required if both inflators are fired.
11.6
MA4014 RE-ARM KIT
11.7
The MA4014 Re-arm Kit, which may be used with the MD4025 FR, is available from Mustang
Survival. The MA4014 Re-arm Kit includes a 60 gr. CO2 cylinder, indicator tab, top and bottom
gaskets and re-arm instructions.
11.8
Two re-arm kits will be required if both inflators are fired.
50
This document is for information purposes only. It is not a controlled
document and may not be considered current when printed.